IE S027FINAL TECHNICAL REPORT AFTER SERVICE-LIFE RUN
Metal-cutting machine tools: accuracy restored without teardown — and it holds
Spindle units regained accuracy, parts came out cleaner, current consumption dropped. 33–50 % — radial and axial runout of the spindle mounting seat; 30 % — radial play of spindle bearings, 0.01–0.03 mm; 25–47 % — surface roughness Ra of parts, 2.2–2.25 → 1.18–1.65 µm; 8.2 % — current draw at cutting modes under load (2014).
plant and XADO commission
Key results
| MACHINE | TYPE | WHAT WAS MEASURED |
|---|---|---|
| IZh 1I611PF-1 | Screw-cutting lathe | Spindle runout, spindle bearing play, ovality and Ra of machined parts, current and power, vibration |
| TV-320 | Screw-cutting lathe | Spindle runout, spindle bearing play, ovality and Ra of machined parts, current and power, vibration |
| 3B151 | Cylindrical grinder | Drive current and power draw, vibration level |
Accuracy: spindle assembly and machined parts
| PARAMETER | MEASURED ON | CHANGE |
|---|---|---|
| Radial and axial runout of the mounting seat | Lathe spindle | Decreased 1.5–2× |
| Radial play of bearings | Lathe spindle | Decreased by 0.01–0.03 mm — 30 % on average |
| Ovality | Reference workpieces | Decreased 1.5–2× |
| Surface roughness Ra | Parts machined on the lathes | 2.2–2.25 → 1.18–1.65 µm |
Reference workpieces were machined at identical cutting modes before and after — the comparison reflects the condition of the machine tool, not the machining mode.
Drive energy consumption and machine vibration
| PARAMETER | MODE | CHANGE |
|---|---|---|
| Current draw | Under load, fixed cutting modes | Reduced by 8.2 % |
| Current draw | Idle run | Reduced by 9.8 % |
| Power draw | Under load, fixed spindle speed | Reduced by 6.2 % |
| Power draw | Idle run | Reduced by 7.1 % |
| Vibration level | All treated machine tools | Reduced by 28–50 % |
Current and power are averaged over the IZh 1I611PF-1, TV-320 and 3B151 machines; before and after readings were taken at identical spindle speeds and cutting modes.
Commission findings
Current equivalent
Revitalizant gel for compressors and bearings →
Piston, screw and centrifugal compressors; rolling and sliding bearings running in an oil bath; machine-tool spindle units and slideways.
How such units are treated:
About this result:
Limits of this report: The results apply to the IZh 1I611PF-1, TV-320 and 3B151 metal-cutting machine tools of the machining shops at SE KhMZ FED and to their normal operating modes; on other equipment and under other modes the figures may differ.